Grounding clamps

ABSTRACT

A grounding clamp is provided. The grounding clamp comprises a body portion having first and second sides, first and second fingers extending from the first side of the body portion, a first set of teeth extending from the first side of the body portion, the first set of teeth positioned between the first and second fingers, and a second set of teeth extending from the second side of the body portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/532,188 filed on Jun. 1, 2017, which is a U.S. National PhaseApplication under 35 U.S.C. 371 of International Application No.PCT/US2015/065243 filed on Dec. 11, 2015, which claims the benefit ofU.S. Provisional Patent Application No. 62/090,862 filed on Dec. 11,2014. The disclosures of these applications are expressly incorporatedherein by reference in their entireties.

FIELD OF THE DISCLOSURE

The present disclosure relates generally to grounding clamps for makingelectrical connection between metal pieces that are mechanically joinedtogether.

RELATED ART

Solar panels are becoming an increasingly popular energy alternative.Solar panel frames, and the mounting rails to which they are fastened,can be made of aluminum. However, the solar panel frames normally haveanodized surface treatment, which insulates the surface from electricalcontinuity. As a result, the solar panels may not be electricallygrounded to the mounting rail. Accordingly, there exists a need in theart for fastening and grounding solar panels with mounting rails.

SUMMARY

The present disclosure relates to grounding clamps. More specifically,the present disclosure relates to grounding clamps having a plurality ofteeth at more than one location for mechanically securing andelectrically connecting one or more solar panel frames to each other andto at least one mounting rail.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features of the disclosure will be apparent from thefollowing Detailed Description, taken in connection with theaccompanying drawings, in which:

FIG. 1 is a top view of a solar panel assembly utilizing groundingclamps of the present disclosure;

FIG. 2 is a side view of the solar panel assembly of FIG. 1;

FIG. 3 is a top perspective view of an end grounding clamp;

FIG. 4 is a bottom perspective view of the end grounding clamp of FIG.3;

FIG. 5 is a forward perspective view of the end grounding clamp of FIG.3;

FIG. 6 is a back perspective view of the end grounding clamp of FIG. 3;

FIG. 7 is a forward perspective view of another end grounding clamp withan extended bottom portion;

FIG. 8 is a top perspective view of an intermediate grounding clamp;

FIG. 9 is a bottom perspective view of the intermediate grounding clampof FIG. 8;

FIG. 10 is a perspective view of another intermediate grounding clampwith a fastener extension;

FIG. 11 is a perspective view of the grounding clamp of FIG. 10 with awire clamp assembled thereto;

FIG. 12 is a perspective view of another intermediate grounding clampwith a grounding wire hole;

FIG. 13 is a view showing a first cut for forming teeth of a groundingclamp; and

FIG. 14 is a view showing a second cut for forming teeth of thegrounding clamp.

DETAILED DESCRIPTION

The present disclosure relates to a grounding clamp, as discussed indetail below.

FIGS. 1-2 are views of a solar panel assembly 110 utilizing groundingclamps of the present disclosure. More specifically, FIG. 1 is a topview of a solar panel assembly 110. As shown, the solar panel assembly110 includes one or more solar panels 112 with an extruded aluminumframe 114 (which could have a hardness of, for example, T6 surfacehardness), mounting rails 116 (guard rails), end grounding clamps 120,intermediate grounding clamps 122, and bolts 124. The solar panels 112are positioned adjacent to one another, and each solar panel 112 issecured to at least one mounting rail 116 using the grounding clamps120, 122 and bolts 124.

The grounding clamps 120, 122 could be made of 300 series stainlesssteel with a temper, for example, of ½ hardness. However, the materialand hardness of the grounding clamps 120, 122 could vary depending onsuch factors as the material and hardness of the solar panel frame 114and mounting rails 116. The grounding clamps 120, 122 could bemanufactured from a single sheet of metal. It is noted that although thegrounding clamps 120, 122 are used in a solar panel assembly 110, thegrounding clamps 120, 122 could be used in any variety of applications,where mechanical and electrical contact between two materials isdesired.

FIG. 2 is a side view of the solar panel assembly 110. As shown, the endgrounding clamps 120 provide a grounding connection between the topsurface of the frame 114 of the solar panels 112 and the mounting rail116. Comparatively, the intermediate grounding clamps 122 provide amechanical and electrical connection between the solar panels 112 (e.g.,between a first solar panel and a second solar panel adjacent thereto).

FIGS. 3-6 are views of an end grounding clamp 120. More specifically,FIG. 3 is a top perspective view of an end grounding clamp 120, FIG. 4is a bottom perspective view of the end grounding clamp 120 of FIG. 3,FIG. 5 is a forward perspective view of the end grounding clamp 120 ofFIG. 3, and FIG. 6 is a back perspective view of the end grounding clamp120 of FIG. 3.

With reference to FIGS. 3-6, the end grounding clamp 120 could of asingle sheet construction manufactured with a series of stamps andbends. The end grounding clamp 120 comprises a vertical wall 126 and atop wall 128 (e.g., body portion having a vertical wall 126 and top wall128) extending therefrom, such that the vertical wall 126 and top wall128 are generally perpendicularly to one another with a bend 130 formedtherebetween. The bend 130 could have one or more stiffening gussets 132formed therein to strengthen the bend 130 (e.g., to provide additionalstructural strength).

The vertical wall 126 comprises a plurality of teeth 134 extending froma bottom thereof (opposite the top wall 128) for penetrating andengaging a mounting rail. The vertical wall 126 includes a firstsidewall 136 bent and extending back from a first side (e.g., left side)of the vertical wall 126, and a second sidewall 138 bent and extendingback (generally perpendicularly) from a second side (e.g., right side)of the vertical wall 126. The sidewalls 136, 138 could be of any depthand could extend for a portion (or all) of the height of the verticalwall 126 (e.g., from the bottom surface of the vertical wall 126). Forexample, the first sidewall 136 could be centrally positioned along thevertical wall 126 and could include a first top taper 140 and a firstbottom taper 142. Similarly, the second sidewall 138 could include asecond top taper 144 and a second bottom taper 146. These sidewalls 136,138 could strengthen the vertical wall 126, thereby preventing bucklingor bending thereof.

The vertical wall 126 could include a tab 148 having a base 150integrally joined with (e.g., bent from) the vertical wall 126 with arounded end 152 opposite the base 150. The tab 148 could extend back(e.g., in the same direction as the top wall 128), such that the tab 148is generally perpendicular to the vertical wall 126. The tab 148includes an aperture 154 at or proximate to the rounded end 152.

In forming the tab 148 of the grounding clamp 120, a first stamp couldremove material, such that the vertical wall 126 and the tab 148 are inthe same plane and define an arced aperture (e.g., U-shaped aperture)therebetween. The tab 148 could then be bent, such that the verticalwall 126 and the tab 148 are in different planes (e.g., perpendicularplanes) and the vertical wall defines an archway aperture 154therethrough. The archway aperture 154 and tab 148 could be any of avariety of shapes. A bottom portion 156 between the archway aperture 154and the teeth 134 could be of any length depending on the height of thesolar panel frame with which the clamp is designed for use.

The top wall 128 could define a through hole 158, where the through hole158 could be centrally located and in vertical alignment with thethrough hole 154 of the tab 148. The vertical alignment allows a bolt togo through both of the through holes 154, 158. This aligns the endground clamp 120 and prevents twisting thereof when assembled (e.g.,with a mounting rail).

The top wall 128 could further include a first finger 160 disposed tothe first side and extending back (away from the bend 130) anddownwardly at an angle relative to the top wall 128. The top wall 128could also include a second finger 162 disposed to the second side andextending back (away from the bend 130) and downwardly at an anglerelative to the top wall 128. The first and second fingers 160, 162contact a top surface of a solar panel frame to keep the solar panelframe in place. The angles of the first finger 160 and second finger 162could be the same.

The top wall 128 could further include a first standoff 165 at the firstside of the top wall 128 extending back (away from the bend 130) anddownwardly (e.g., substantially perpendicularly) relative to the topwall 128. The top wall 128 could further include a second standoff 167at a second side of the top wall 128 extending back (away from the bend130) and downwardly (e.g., substantially perpendicularly) relative tothe top wall 128. The standoffs 165, 167 contact a side surface of asolar panel frame. The standoffs 165, 167 further assist in installationof the grounding clamp 120 (e.g., vertically aligning the end groundingpanel clamp 120) and create space between the vertical wall 126 and tab148 of the grounding clamp 120 and a side of a solar panel frame.

The top wall 128 could further include a back extending central portion164 disposed between the first finger 160 and second finger 162, thecentral portion 164 extending back (away from the bend 130) anddownwardly from the top wall 128. The central portion 164 could be bent(e.g., 45°), angled, rolled, or curved relative to the top wall 128. Theback extending central portion 164 could include a plurality of teeth166 extending from the end thereof (e.g., away from the body portion)for penetrating and engaging a solar panel frame. Placing the pluralityof teeth 166 at an angle provides for better penetration of the teeth166 because a single point of each tooth (e.g., defined by the sides ofthe tooth 166 and the bottom surface of the top wall 128) contact andpenetrate the solar panel frame (as opposed to the edge formed by thesides of the teeth 166).

The angles and/or lengths of the fingers 160, 162 and central portion164 could vary depending on size and characteristics of the panels andmounting rails (e.g., the central portion 164 could be shorter in lengththan the fingers 160, 162). In this way, at least a portion of the teeth166 of the central portion 164 penetrate a solar panel frame.

FIG. 7 is a back perspective view of another end grounding clamp 320with an extended bottom portion 356. Similarly to the grounding clamp ofFIGS. 3-6, the grounding clamp 320 includes a vertical wall 326 withsidewalls 336, 338, a tab 350 with a through hole, and a plurality ofteeth 334, as well as a top wall 328 integrally connected with thevertical wall by a bend 330, the top wall 328 including a through hole,first and second fingers, first and second standoffs, and a centralportion having a plurality of teeth disposed between the fingers. Thelength of the extended bottom portion 356 of the grounding clamp 320could vary depending on the height of the solar panel frame (e.g., athicker solar panel frame requires a taller grounding clamp).

FIGS. 8-9 are views of an intermediate grounding clamp 422. Morespecifically, FIG. 8 is a top perspective view of an intermediategrounding clamp 422, and FIG. 9 is a bottom perspective view of theintermediate grounding clamp 422 of FIG. 8. The intermediate groundingclamp 422 includes a body portion 470 with a through hole 472 therein(e.g., centrally located in the body portion 470). The body portion 470includes a first spacer 474 extending from a first side of the groundingclamp 422 downwardly (towards the bottom surface) at an angle relativeto the body portion 470, as well as a second spacer 476 extending from asecond side (opposite the direction of the first spacer 474) of thegrounding clamp 422 downwardly at an angle relative to the body portion470. The angles of the first spacer 474 and second spacer 476 could bethe same. The width of the spacers 474, 476 could vary depending on thedesired spacing between the solar panels.

Further, the grounding clamp 422 includes a plurality of fingers. Morespecifically, the grounding clamp 422 includes a first forwardlyextending finger 478 disposed towards the first side of the groundingclamp 422 and extending downwardly at an angle relative to the bodyportion 470, and a second forwardly extending finger 480 disposedtowards the second side of the grounding clamp 422 and extendingdownwardly at an angle relative to the body portion 470, such that thefirst and second forwardly extending fingers 478, 480 extend in the samedirection. The grounding clamp 422 further includes a first backextending finger 482 disposed towards the first side of the groundingclamp 422 and extending downwardly at an angle relative to the bodyportion 470, and a second back extending finger 484 disposed towards thesecond side of the grounding clamp 422 and extending downwardly at anangle relative to the body portion 470, such that the first and secondback extending fingers 482, 484 extend in the same direction. Theforwardly extending fingers 478, 480 extending from an opposite side ofthe intermediate grounding clamp 422 as the back extending fingers 482,484. The fingers 478, 480, 482, 484 could be of the same length and/orwidth, and could be longer or shorter than the spacers 474, 476. Theangles of the fingers 478, 480, 482, 484 could be the same, and/or couldbe greater or less than the angles of the spacers 474, 476. The firstforwardly extending finger 478 and first back extending finger 482 couldbe adjacent each other and could extend from the body 470 atperpendicular directions. Similarly, the second forwardly extendingfinger 480 and second back extending finger 484 could be adjacent eachother and could extend from the body 470 at perpendicular directions.

The grounding clamp 422 could further include a forwardly extendingcentral portion 486 disposed between the first and second forwardlyextending fingers 478, 480 and extending downwardly at an angle relativeto the body portion 470. Similarly, the grounding clamp 422 couldfurther include a back extending central portion 488 disposed betweenthe first and second back extending fingers 482, 484 and extendingdownwardly at an angle relative to the body portion 470. The centralportions 486, 488 could be bent, angled, rolled, or curved relative tothe body portion 470. The central portions 486, 488 could be of the samelength and/or width. The angles of the central portions 486, 488 couldbe the same. The angles and/or lengths of the spacers 474, 476, fingers478, 480, 482, 484, and/or central portions 486, 488 could varydepending on size and characteristics of the panels and mounting rails(e.g., the central portions 486, 488 could be shorter in length than thefingers 478, 480, 482, 484).

The forwardly extending central portion 486 could include a firstplurality of teeth 490 extending from the end thereof (e.g., away fromthe body portion 470) for penetrating and engaging a solar panel frame,and the back extending central portion 488 could include a secondplurality of teeth 492 extending from the end thereof (e.g., away fromthe body portion 470) for penetrating and engaging a solar panel frame.Placing the plurality of teeth 490, 492 at an angle provides for betterpenetration of the teeth 490, 492 because a single point of each tooth(e.g., defined by the sides of the tooth 490, 492 and the bottom surfaceof the intermediate grounding clamp 422) contacts and penetrates thesolar panel frame (as opposed to the edge formed by the sides of theteeth 490, 492). In this way, at least a portion of the teeth 490, 492of the central portions 486, 488 penetrates a solar panel frame. Morespecifically, the first plurality of teeth 490 of the forwardlyextending central portion 486 penetrates and engages a first solar panelframe, and the second plurality of teeth 492 of the back extendingcentral portion 488 penetrates and engages a second solar panel frame,thereby mechanically and electrically connecting the first and secondsolar panel frames to one another.

FIGS. 10-11 are views of an intermediate grounding clamp 522. Morespecifically, FIG. 10 is a top perspective view of an intermediategrounding clamp 522 with a fastener extension, and FIG. 11 is a bottomperspective view of the intermediate grounding clamp 522 of FIG. 10. Asdescribed above, the intermediate grounding clamp 522 includes a bodyportion 570 with a through hole 572, a first spacer 574, second spacer576, a first forwardly extending finger 578, a second forwardlyextending finger 580, a first back extending finger 582 a second backextending finger 584, a forwardly extending central portion 586 with afirst plurality of teeth 590, and a back extending central portion 588with a second plurality of teeth.

The second spacer 576 further includes a fastener extension 577protruding from an end thereof (away from the body portion 570), and atan angle such that the fastener extension 577 is substantially parallelwith the body portion 570. The fastener extension 577 includes first endportion 579 integrally connected with and extending from the secondspacer 576, and second end portion 581 opposite thereto. The first andsecond end portions 576, 581 could be of the same or substantiallysimilar widths. In between the first and second end portions 579, 581 isa neck 583 (e.g., recessed portion), which has a width thinner than thewidth of first and second end portions 579, 581. The fastener extension577 could be bent at an angle along the length thereof to define achannel 585 in the lower surface thereof.

As shown in FIG. 11, a wire clamp 587 (e.g., grounding wire clamp) couldbe positioned around the neck 583 of the fastener extension 577. Thewire clamp 587 could be a loop of metal with at least one threadedthrough hole (e.g., a hole at each end of the strip of metal forming theloop) for a bolt 589 (e.g., screw). The wire clamp 587 could form asubstantially rectangular loop. When the wire clamp 587 is positionedaround the neck 583 of the grounding clamp 522, a grounding wire couldbe threaded through the wire clamp 587, and positioned beneath thefastener extension 577 (along the channel 587). Tightening the bolt 589of the wire clamp 587 creates more distance between the top surface ofthe fastener extension 577 and the top of the wire clamp 587, whichcreates less distance between the bottom surface of the fastenerextension 577 and the bottom of the wire clamp 587, thereby securing thegrounding wire between the wire clamp 587 and the fastener extension577. This keeps the grounding wire centered and secured.

FIG. 12 is a perspective view of another intermediate grounding clamp622 with a grounding wire hole. As described above, the intermediategrounding clamp 622 includes a body portion 670 with a through hole 672,a first spacer 674, a first forwardly extending finger 678, a secondforwardly extending finger 680, a first back extending finger 682 asecond back extending finger 684, a forwardly extending central portion686 with a first plurality of teeth 690, and a back extending centralportion 688 with a second plurality of teeth.

The intermediate grounding clamp 622 further includes a rounded end 691extending from a second side (opposite the direction of the first spacer574) of the grounding clamp 522. The rounded end 691 and body portion670 define a grounding wire through hole 693 (e.g., threaded). Agrounding wire can be threaded through the grounding wire through hole693, which secures the grounding wire to the intermediate groundingclamp 622. A lay-in lug could be attached to the grounding wire throughhole 693 (e.g., by a screw threaded into the grounding wire through hole693).

FIGS. 13-14 are views of a cutting tool 711 forming teeth using a crosscut. A cutting tool 711 has a plurality of cutting teeth 713. The peaksand valleys of the cutting teeth 713 may not be perfect points, andinstead could be rounded to a degree (e.g., a limitation of theirmanufacturing process). To form teeth 717 from sheet metal 715 that aresharper than the cutting teeth 713 of the cutting tool 711, a cross cutcould be used.

FIG. 13 is a view showing a first cut for forming teeth of a groundingclamp. Stamping using the cutting teeth 713 of cutting tool 711 forms afirst set of teeth 717, which have the same (or substantially similar)properties (e.g., profile) as the cutting teeth 713. The first set ofteeth 717 have similarly sharp peaks and valleys as those of the cuttingteeth 713.

FIG. 14 is a view showing a second cut for forming teeth of thegrounding clamp. More specifically, after forming the first set of teeth717, the cutting tool 713 is shifted so that the cutting teeth 713 arepositioned midway between the first set of teeth 717 (e.g., the peaks ofthe cutting teeth 713 are in line with the peaks of the first set ofteeth 717). This produces a second set of teeth 719. The valleys of thesecond set of teeth 719 are similarly shaped as the valleys of cuttingteeth 713, however, the peaks of the second set of teeth 719 are muchsharper than that of cutting teeth 713. This is due to the fact that thepeaks of the second set of teeth 719 are formed by the straight sides ofthe cutting teeth 713.

Having thus described the disclosure in detail, it is to be understoodthat the foregoing description is not intended to limit the spirit orscope thereof. It will be understood that the embodiments of the presentdisclosure described herein are merely exemplary and that a personskilled in the art may make any variations and modification withoutdeparting from the spirit and scope of the disclosure. All suchvariations and modifications, including those discussed above, areintended to be included within the scope of the disclosure.

The invention claimed is:
 1. A grounding clamp for a solar panel array,comprising: a body having top and bottom surfaces, first and secondends, and first and second sides, first and second end fingers extendingfrom the first and second ends of the body at a first angle in adirection away from the bottom surface and positioned between adjacentsolar panel frames of a solar panel array; first and second pairs ofside fingers extending from the first and second sides of the body at asecond angle in a direction away from the bottom surface and positionedagainst upper surfaces of adjacent solar panel frames of a solar panelarray; first and second sets of teeth positioned on the first and secondsides of the body, the first set of teeth positioned between the firstpair of side fingers, and the second set of teeth positioned between thesecond pair of side fingers, the first and second sets of teethextending from the body at a third angle in a direction away from thebottom surface to penetrate top surfaces of adjacent solar panel framesof a solar panel array; and a central aperture in the body configured toreceive a bolt to secure the grounding clamp and adjacent solar panelframes of a solar panel array to a mounting rail, whereby the groundingclamp secures together and grounds adjacent solar panel frames of asolar panel array.
 2. The grounding clamp of claim 1, wherein thegrounding clamp is manufactured from a single sheet of metal.
 3. Thegrounding clamp of claim 1, further comprising a second aperture toreceive a grounding wire therethrough.
 4. The grounding clamp of claim1, wherein one of the first or second end fingers includes a fastenerextension extending from an end of the one of the first or second endfingers, the fastener extension having a narrowed neck to receive a wireclamp.
 5. A grounding clamp for a solar panel array, comprising: a bodyhaving top and bottom surfaces, first and second ends, and first andsecond sides, first and second end fingers extending from the first andsecond ends of the body at a first angle in a direction of the bottomsurface and positioned between adjacent solar panel frames of a solarpanel array; first and second pairs of side fingers extending from thefirst and second sides of the body at a second angle in a direction ofthe bottom surface and positioned against upper surfaces of adjacentsolar panel frames of a solar panel array; first and second sets ofteeth positioned on the first and second sides of the body, the firstset of teeth positioned between the first pair of side fingers, and thesecond set of teeth positioned between the second pair of side fingers,the first and second sets of teeth extending from the body at a thirdangle in a direction of the bottom surface to penetrate top surfaces ofadjacent solar panel frames of a solar panel array; a central aperturein the body configured to receive a bolt to secure the grounding clampand adjacent solar panel frames of a solar panel array to a mountingrail; and a second aperture to receive a grounding wire therethrough;whereby the grounding clamp secures together and grounds adjacent solarpanel frames of a solar panel array.
 6. A grounding clamp for a solarpanel array, comprising: a body having top and bottom surfaces, firstand second ends, and first and second sides, first and second endfingers extending from the first and second ends of the body at a firstangle in a direction of the bottom surface and positioned betweenadjacent solar panel frames of a solar panel array; one of the first orsecond end fingers includes a fastener extension extending from an endof the one of the first or second end fingers, the fastener extensionhaving a narrowed neck to receive a wire clamp; first and second pairsof side fingers extending from the first and second sides of the body ata second angle in a direction of the bottom surface and positionedagainst upper surfaces of adjacent solar panel frames of a solar panelarray; first and second sets of teeth positioned on the first and secondsides of the body, the first set of teeth positioned between the firstpair of side fingers, and the second set of teeth positioned between thesecond pair of side fingers, the first and second sets of teethextending from the body at a third angle in a direction of the bottomsurface to penetrate top surfaces of adjacent solar panel frames of asolar panel array; and a central aperture in the body configured toreceive a bolt to secure the grounding clamp and adjacent solar panelframes of a solar panel array to a mounting rail; whereby the groundingclamp secures together and grounds adjacent solar panel frames of asolar panel array.